Building construction



July 11, 1939 G. F. Ko'lrRBA'rY 2,166,095

BUILDING CONSTRUCTION ATTORNEY July 11,1939- l G. F. KOTRBATY BUILDING CONSTRUCTION Filed July s1, 1937 2 sheets-sheet 2 v /N VENTO/e Guy F Korbal'y Patented July 11, '1,939

UNITED STATES PATENT OFFICE 18 Claims.

This invention relates to improvements in selfsupporting building units adapted for use in walls and flooring, as well as on roofs and ceilings, and the application relates more particularly to such units having semi-stud and beam sections as the fao load-supporting structural elements, normally spaced apart and held by a single panel, abutted semi-stud or beam elements being secured together as structural composites, and the open faces of the units being surfaced with continuous sheathing or other surfacing materials, including individual panelings.

The present invention is concerned With structural units in which the side members form structural building sections when abutted and interlocked with juxtaposed like elements. The so-formed composite structural supporting members may be spaced on a given modulus and secured together by panelings or wall members to form a single lface or Wall section of an open building unit, which unit will comprise two end structural composite stud or beam elements, and an intermediate wall, flooring, ceiling or roofing panel section. The panels may be secured to the side or structural supporting members, as by singl-e face supported on composite structural.

stud or beam elements. The locking keys used may have furring strips, sleepers, or other nailing members secured thereto. At the open sides or faces of the assembled units, and nailable :surfacings may be secured to such nail-receiving members Such a construction permits the use of the customary nailable surfacings, including sheathing, c1apboarding,wall boards, insulating panels or mountings, plasterers lath, or plaster panels, all with or without preformed or diagrammed nailing holes, and other structural or ornamental surfacing members to the open faces of the units, including my self-supporting units generally and the composite structural stud,stanchion and beam members of walls and floors. This provides a desired and practicable extension of the building principles and structures set out in my (Cl. 18S-34) prior patents and pending applications, and including the common fundamental constructional principle of modular construction.

The use of an open-faced structural member having two structural -end sections lends itself very readily to use in so-called prefabricated or preformed houses, in which the several parts may be designed or cut for rapid and eflicient assembly and fabrication. As an adjunct of this facility of design, fabrication, and erection, the in- 1 ner or outer panels of any given wall, floor, ceiling, or attic unit, may be suitably stenciled to indicate diagrams for the layout and erection of plumbing pipes and fixtures, piping and other xtures for heating systems and air conditioning devices, which diagrams Will indicate the proper position of various services and component parts when the house is under erection. Itwill,of course, be appreciatedthata wide variety of plans, layouts and diagrams' including catalogue designations of parts and bills of materials, may be stencilled, printed, or lithographed on either or both sides of these panel members.4 Such indicia may include diagrams for radio installations, television, fire-alarm, burglar alarm, telephone wiring or call bell systems wiring diagrams or plans of a multitude of other devices, services or wiring layouts, diagrams or plans. The panels, may, of course, include nailing diagrams. In addition, the present invention comprehends the marking of the outer surfaces of such panels with diagrams, and the like, indicating the position of sinks, flush tanks, lavatories, bowls, fixtures for telephone and lighting, including switches and switch and control boxes, as well as brackets and hangers, and other auxiliary structural elements associated with the services delineated on the reverse side of the panel.

The composite stud and beam sections of the present invention may assume a variety of forms and include hollow stud and beam members having sections adapted for mutual interlocking, and other sections adapted to be secured together by common keying means, which keying means may include members for receiving Vcontinuous wall, floor, and ceiling surfacings. These and other desirable features and advantages of the present invention will be described hereinafter with respect to the drawings accompanying thepresent specification and forming a part thereof, it being understood thatthe examples set forth are given by way of illustration only, for, since the underlying principles may be embodied in other specie structural devices,"it is not intended to be limited to the structures here shown, except as 55 such limitations are clearly imposed by the appended claims.

In the drawings, like numerals refer to similar parts throughout the several views, of which Fig. l is an elevation of a plurality of assembled wall units having floor hanging connections, and the inner faces of the panels being stenciled to designate proper positioning of plumbing and other building service facilities;

Fig. 2 is a perspective of the upper portion of a composite stud member as shown in Fig. l;

Fig. 3 is an elevation, partly in section, of a plurality of assembled units keyed together and having continuous surfacing applied on and over the open sides of the units;

Fig. l is a horizontal cross-section of the stud members and keying members used in Fig. 3, together with the furring strips or sleepers for receiving the continuous surfacing;

Fig. 5 is a View similar to Fig. 3, and showing a modified key and furring strip or sleeper-securing member;

Fig. 6 is a view similar to Fig. 4 showing the modified keying member of Fig. 5, and

Fig. 7 is a detail of a rst floor joint connection showing floor members supported on a basement wall and wall members supported from the oor members.

Referring more specifically to the drawings, the improved structural building members of the present invention comprise units, designated generally by the numeral |00, and including single panel or wall sections, |0I, secured to and spacing composite end stud elements, designated generally by the numeral IIO. The composite stud or structural members, IIO, comprise channel shaped sections, III, II2, each having flanged sides, I I3, I I4, abutted and locked together by an angular flange, IIS, fitted into and secured by hook liange, I I 5. The other side of the composite unit comprises a pair of at hook flanges, II'I, IIS, usually spaced apart, as indicated at I I9, by a longitudinal slot. The hook flanges, II'I, IIB, are substantially equal in width to the sides of the channel sections, I II, ||2, and are adapted to be secured together and locked by flat keys, |20, having edge hook anges I2 I, |22. The key members, |20, may have wooden or other furring strips, sleepers, or like members |30, adapted for nail-receiving, fastened on the outside of the keys, as by means of nails or other securing members, designated generally by the numeral 53|. Suitable cementing agents and glues may also be used for this purpose, and narrow panel sections or strips of wood, including plywood, may be applied thereto.

The panel members, |0|, as indicated above, are secured to the side flanges, II 3, II4, of the stud sections, as by means of bolts, rivets, screws, screw-nails, or the like, or by means of suitable waterproof cements and glues, all designated generally by the numeral |02. The sections I I I, I I2, of the stud members may be provided with a variety of apertures, all designated generally by the numeral ||0a. By cutting down the volume of metal in sections III, |I2, without decreasing their structural strength and efliciency, a desirable insulating effect is produced in the members, as the restriction or lessening of the heat conducting metal available imposes a certain resistance to the conduction of heat therethrough. This effect is important, as it tends to minimize condensation effects in the interior of Walls, and particularly of exterior walls.

The (pen faces of the abutted and aligned units, |00, are held locked together by the key members, |20, coacting with the hook flanges, I I1, I I 8, of the rail sections of the composite stud member, ||0. Individual panels or continuous wall surfacings or coverings may be applied on and over the furring strips or sleepers, |30, which are secured to the key members, |20. These surfacings may include inner sheathings, |32, over which may be applied any suitable plastic or other surfacing material, designated generally by the numeral |33. Other surfacings may be applied thereto, and including metal, wood, paperencased gypsum panels, plaster or stucco lath, which latter may be covered with plastic materials or brick or sto-ne veneer. The continuous sheathing, or other like structural wall surfacing, completes the wall structure and insures rigidity to the wall assemblies. The material used for the sheathing and surface nishings may vary, depending more upon whether or not the units form part of inner supporting or partition walls, or whether they form part of outside Walls which are required to be finished with weather-resistant surfacings. In the latter instance, it will be understood that tar-paper and other water-proofing underlays may be associated with the sheathing, |32, and the surface nishing, |33. Furring strips cr sleepers, |30, of the assembly serve as auxiliary vertical or horizontal supporting members in the composite structural members, IIl, and, at the same time, serve as supports for surface finish and supporting members, such as the sheathings, |32, and associated surfacing, |133. The abutted panels, I 0 I, of adjacent units are desirably directly abutted to give a line seam Ila, particularly in cases where the paneling material, I0 I, may be made of veneering and have a desirable surface finish. Any seams or joints formed may be filled with a filler putty or cement and parkled before painting or finishing of the surace.

The units, |00, may be set in channel members adapted to receive the composite stud members, ||0, and secured therein by concrete or other hardenable structural plastics, or by mechanical means, such as bolts and nuts, as well as by rivets, screws, screw-nails, and also by means of spot welding. Usually and desirably, the panel members, IUI, will be cut away a suiiicient distance, top and bottom, to' permit the composite structural members, III), to extend therebeyond and t into the channels at the bottom and receive cap members at the top, as well as to receive floor hanger members, |40, at the top and bottom thereof. These hanger members comprise a generally continuous body section, I4I, secured to the stud members, as by means of spot welds, I t2, and being provided at the top and bottom thereof with an offset flange |43, and a hook flange, |44, which are generally in vertical alignment. The flanges, |43, |44, of the hanger member, |130, are adapted to be received in and locked by like members placed in reverse position on floor sections and other structural building members which are to be hung on the wall. Where the walls are to be hung from the iioors, the posi-- tion of the hanger members, with respect to each other, will, of course, bereversed, as indicated more in detail in Fig. 7. As shown in this gure, the basement wall 200 serves as a foundation for the building. On this wall-flooring, members, designated generally by the numeral 400, are set. These members include hanger members |40 secured across the ends thereof and with the flanges |43, |44 directed vertically upward, while the corresponding hanger members secured to stud sections III) of wall unit are arranged to have the hook iiang'es |113, |44 directed vertically downward. By this arrangement, as noted above, the wall units |00 are adapted to be hooked on to and supported by floor units 400, and due to the weight of the wall units, a permanent aligned connection is assured for the entire structure. The hanger members and the method of forming wall and floor joints therewith are described and claimed in my copending application, S. N. 108,956, iiled Nov. 3, 1936, for Buildings and mechanical joints therefor, and will not be described further herein, except to show the general combination and association with the structural building units. In this connection, it is to be noted that the hanger members, |40, act as horizontal bracing members for each unit, and, thus, for the entire structure, and will prevent weaving or lateral Vibration, particularly at the vertical joints. The hanger members may also be used in continuous lengths, overlapping or extending over a plurality of abutted units and providing a com# mon, lateral bracing construction.

As noted hereinabove, a desirable feature in the designing and erection of so-called prefabricated or planned houses is the provision of stencilings, |50, indicating the exact position and layout of all plumbing, wiring and other maintenance -services required in a house or other structure.

The several stencilings may vary from one unit to another, depending upon the parts which are secured therein or thereto, and which insure absolute accuracy of iit and correctness of perv formance. It is to be noted further that all holesV may be pre-drilled or pre-punched, and, where necessary, the holes receiving screw fastening members may be thread tapped. The prepunched or pre-drilled holes will provide for passage of pipe ducts, wires, and other elements, through the panels, thereby cutting down the time normally required for such work to be done in the field, and doing away with the botchy appearance of such work. All of this lends to uniformity of design, fabrication and erection, and, at the same time, insures to all parties involved, maximum speed in erection and tting, while, at the same time, insuring absolute correctness and greatly increased eiiiciency in the assembly, which, from y the sanitary and safety point of view, is of prime importance. Standardization of. erection, consequent upon the standardization of parts permitted by this novel method, also permits standardization of replacement members, and absolute and complete accuracy in their identification andreplacement. The plumbing and other services may have their outlets on either surface of the units, and may extend through several units, horizontally, passing through the apertures, Illia, in the supporting members, I I 0.

Referring now to Figs. and 6, a modied locking and securing of the furring strip or sleeper members, |30, is provided. In this construction,`

the stud units, Ilbl, have the usual elements of composite structural member, III), with the exception that the hook flanges, II'I, ||8, are continued vertically in alignment with sides, I I, I I2, to form flanges, II'Ia, |l8a, which respectively terminate in inturned hook flanges, II'Ib and ||8b. A channel shaped keying member, |25, has the usual furring strip or sleeper or other nailing member, |30, secured therein by securing means, I3I, and its sides, |26, |21, extend beyond the furring strip or sleeper and are adapted to fit in sliding contact with the hook flanges, ||1b,

Hab, and v10e iockd therein and thereby. This arrangement provides a lateral locking support for the members, |30, while, at the same time, permitting ready access toI the same for the purpose of securing sheathing, paneling, and other suriacings thereto.

It will now be appreciated that there have been provided novel structural building members including unitary constructions having a paneling and structural end members secured thereto, abutted end members of adjacent sections forming composite structural members, which, in turn, are locked in place by keying members having means associated therewith to receive continuous wall surfacings, or individual panels, closing the open faces of the units and completing a wall, floor, or roof assembly. In addition, oor hanging and securing members are associated with the assembly of units to secure oors thereto or to hang walls thereon, and, at the same time, to provide a ldesirable lateral bracing to a structure made therefrom.

What is claimed is:

1. A continuous building section, comprising an array of self-supporting building units, each unit including a single face or panel section secured to and spacing end structural elements, the juxtaposed end elements of abutted units forming composite structural members; means in the end elements for cooperative engagement with complementary elements, and locking means joining the several juxtaposed end elements at the free edges thereof.

2. In a. construction of the type claimed in claim 1, the improvements comprising aligned apertures in juxtaposed end elements of abutted units, said apertures decreasing the volume of metal in the sections and increasing the insulating effect therein by affording a lessened degree of conductivity between the edges thereof, as well as minimizing condensation effects upon the surfaces adjacent to the edges of the said elements.

3. In a construction of the type described in claim 1, the improvements comprising nail-receiving members associated with the free edge locking means of the units.

4. In a construction of the type claimedin claim 1, the improvements comprising nail-receiving members associated with the free edge locking means of the units, and surfacing members over the nail-receiving members and secured thereto, and closing the open sides or faces of the juxtaposed units.

5. A structural building unit comp-rising a pair of end supporting members, each forming an element of a composite structural supporting stud and beam member, means on at least one edge l of the end members to receive and secure panel members and at one edge thereof and forming a three element unit therewith; and keying means at the other edge of the end members.

6. A structural building unit comprising a pair of end supporting members, each forming an element of a composite structural supporting stud and beam member; means in the said end members for locking engagement with abutted like sections of juxtaposed building units; a panel member secured to and spacing the end members and forming a three element building unit therewith.

'7. A continuous building section comprising an array of self-supporting building units, each unit including a single face or panel section secured to and spacing end structural elements of composite hollow structural members, the composite `hook flanges substantially continuous with the structural building member comprising a pair of channel sections, one of said sections having an inturned flange at one side thereof and the abutting channel member having a hook flange in mating engagement with the first said flange, the opposite sides of the channels being provided with parallel hook flanges, a double hook flanged flat key in locking engagement with the side hook flanges and nailable supporting means mounted on the at key.

8. A continuous building section comprising an array of three-part, self-supporting building units, each unit including a single face or panel section secured to and spacing end structural elements of composite hollow structural vmembers, the composite structural building member comprising a pair of channel sections, one of said sections having an inturned flange at one side thereof and the abutting channel member having a hook flange in mating engagement with the first said flange, the opposite sides of the channels being provided With parallel hook flanges, a double hook flanged at key in locking engagement with the side hook flanges, and nailable supporting means mounted on the at key, the channel elements having transverse apertures and forming hollow composite supporting members.

9. A continuous building section comprising an array of self-supporting building units, each unit including a single face or panel section secured to and spacing end structural elements of composite hollow structural members, the composite structural building member comprising a pair of channel sections, one of said sections having an inturned flange at one side thereof and the abutting channel member having a hook flange in mating engagement with the first said flange, the opposite sides of the channels being formed of raised rib sections terminating in everted at faces of the channel sections, a channel shaped key member in locking engagement with the said flat hook flanges and a nailable support disposed in the said channel key member.

10. In a building construction of the type described in claim 7, the improvements comprising a common wall surfacing over the open faces of the said assembly of units and secured to and on the said structural members, end structural hanger members secured to and on the structural members kat floor level height and forming lateral bracing elements for the building units.

11. In a building construction of the type described in claim 8, the improvements comprising a common wall surfacing over the open faces of .the said assembly of units and secured to and on the said structural members, end structural hanger members secured to and on the structural members at floor level height and forming lateral bracing elements for the building units.

12. In a building construction of the type described in claim 9, the improvements comprising a common Wall surfacing over the open faces of the said assembly of units and secured to and on the said structural members, and structural hanger members secured to and on the structural members at floor level height and forming lateral bracing elements for the assembled units.

13. A self-supporting building unit comprising a single face or panel section secured toI and spacing end structural elements of composite member comprising a pair of channel sections, one of said sections having an inturned flange at one side thereof and the abutting channel member having a hook flange in mating engagement With the rst said flange, the opposite sides of the channels being provided with parallel hook flanges, a double hook flanged flat key in locking engagement with the side hook flanges and nailable supporting means mounted on the flat key, the channel elements having aligned transverse apertures and forming hollow composite supporting members.

14. A self-supporting building unit comprising a single face or panel section secured to and spacing end structural elements of composite hollow structural members, the composite structural building member comprising a pair of channel sections, one of said sections having an inturned flange at one side thereof andthe abutting channel member having a hook flange in mating engagement with the first said flange, the opposite sides of the channels being formed of raised rib sections terminating in everted flat hook flanges substantially continuous with the faces of the channel sections, a channel shaped key member in locking engagement with the said flat hook flanges and a nailable support disposed in the said channel key member.

15. In a building construction of the type described in claim 7, the improvements comprising a common wall surfacing over the open faces of each unit of the said assembly of units and secured to and on the said structural members, and structural hanger membersl secured to and on the structural members at oor level height and forming lateral bracing elements for the build ing units.

16. In a building construction of the type described in claim 8, the improvements comprising a common wall surfacing over the open faces of each unit of the said assembly of units and secured to and on the said structural members, end structural hanger members secured to and on the structural members at oor level height and forming lateral bracing elements for the building units.

17. In a building construction of the type described in claim 9, the improvements comprising a common wall surfacing over the open faces of the said assembly of units and secured to and on the said structural members, end structural hanger members secured to and on the structural members at floor level height and forming lateral bracing elements for the assembled units.

18. A building construction, comprising a foundation wall assembly, iioor units laid on and supported by the foundation, the said floor units be ing provided with structural hanger members secured on and across the ends of the unit and having the hanger elements directed vertically upward, wall units provided with structural hanger members at the bottom thereof and arranged with the hanger elements disposed vertically downward and in aligned slip t locking relationship with cooperating elements of the floor members whereby the Wall units are supported on and by the :door members in aligned relationship, the said wall units comprising end structural members and single panel members spacing the end members and secured thereto to form three element units having open faces, the abutted units being interlocked by keying means, and continuous wall surfacings over the o-pen faces and secured to the keying members.

GUY FELIX KOTRBATY. 

